Non-Ferrous Metals

Made by:

Natasha
Julia
Pavan
Vamshi
Abhishek
Non-ferrous Metals
Non ferrous metals – as the name suggests it does not
have the chemical element IRON in appreciable
amounts.
It is generally more expensive than ferrous metals.
It has higher conductivity, low weight, resistance to
corrosion
Few non ferrous materials are also used in iron and steel
industries
Eg .  bauxite is used as flux for blast furnaces, while
others such as wolframite, pyrolusite and chromite are
used in making ferrous alloys.
Types of non ferrous metals
Non ferrous metals include
• Aluminium
• Copper Among these we are
• Lead going to study about:
Aluminium
• Tin Copper
• Titanium Tin
• Nickel Lead
Zinc
• Zinc
Basic idea on ores
An ore is a special type of rock that contains a large enough
amount of a particular mineral (usually a metal) to make it
economically practical to extract that mineral from the
surrounding rock. Not all minerals are found in a large
enough amount in one location to make it worth it to remove
the ore from the rock, through a process known as mining.
The rock will be extracted and processed in a variety of
ways (depending on the type of mineral) to remove the
mineral from the surrounding rock. Once they are extracted
and processed, the minerals can be turned into whatever
products are desired
Types of ores

Ores are classified based on how they form. Some

ores form from the cooling and crystallization of
minerals within magmas, lavas, or igneous intrusions.
These are known as magmatic or volcanic ores.
Nickel, copper, and iron ores are typically formed
from magmatic or volcanic related
deposits. Carbonate alkaline ores are formed from
other igneous processes other than volcanic and
activity. Rare earth element ores and also some
diamonds are part of the carbonate alkaline group.
Magmatic ore

Volcanic ore

Carbonate alkaline ore

 If ores can form from igneous processes, then they can
also form from metamorphic or sedimentary processes
also. Metamorphic ores often contain lead, zinc, and
silver, as well as some iron oxides. Sedimentary
ore deposits include banded iron formations, and gold,
platinum, zinc, tin, and even diamond-containing ores
that formed in sedimentary environments. Lastly, ores
can form as a result of hydrothermal processes. These
processes involve the exposure of rocks and minerals to
extremely hot water, usually near oceanic hydrothermal
vents or hot springs. Most of the world's gold ores, as
well as uranium ores, formed from hydrothermal
processes.
Metamorphic ore

Sedimentary ore
Physical properties of Aluminium
•It is soft, durable, light weight,
ductile and malleable metal.
•Appearance-silvery to dull grey
(depends upon surface roughness)
•Non magnetic and does not easily ignite
•The yield strength of pure aluminium is 7–11 Mpa.
•Aluminium alloys have yield strengths ranging from 200
MPa to 600 MPa.
•Is easily machined, cast, drawn and extruded.
•Aluminium is a good thermal and electrical conductor,
having 59% the conductivity of copper, both thermal and
electrical, while having only 30% of copper's density.
Name: Aluminum
Symbol: Al
Atomic No.:13
Atomic Weight:26.98gm
Phase: Solid
Melting Point: 660.32ºc
Boiling Point : 2470ºC
Chemical properties of Aluminium

• Passivation- Corrosion resistance can be excellent

because a thin surface layer of aluminium oxide forms
when the bare metal is exposed to air, effectively
preventing further oxidation.
• The strongest aluminium alloys are less corrosion
resistant due to galvanic reactions with alloyed copper.
• This corrosion resistance is greatly reduced by aqueous
salts, particularly in the presence of dissimilar metals.
• Aluminium is one of the few metals that retains silvery
reflectance in finely powdered form, making it an
important component of silver-colored paints.
Uses of Aluminium
Etched surface from a high
purity (99.9998%)
aluminium bar, size 55×37
mm

Aluminium-
bodied Austin "A40Sports"c.
1951)

Household aluminium foil

• Transportation as sheets tubes and castings for
trucks, aircraft, cars; etc.
• Packaging (cans, foil, frames)
• Construction of windows, doors, siding, building
wire, sheathing, roofing, etc.
• Street lighting poles, sailing ship masts, walking
poles.
• Electrical transmission lines for power
distribution
• In manufacture of electrical conductors
• Etc.
Manufacture of Aluminium
• It is extracted from
bauxite ores
• The bauxite is ground and
then it is purified.
• It is then dissolved in fused
cryolite which is a double
fluoride of aluminium and
sodium,AlF3, 3NaF.
• This solution is taken to an
electric furnace and the
aluminium is separated out
by electrolysis.
Physical properties of Copper

• Has high ductility, electrical and thermal conductivity.

• Copper is usually supplied in a fine-
grained polycrystalline form, which has greater strength than
monocrystalline forms.
• The softness of copper partly explains its high electrical
conductivity (59.6×106 S/m) and high thermal conductivity,
second highest (second only to silver) among pure metals at
room temperature.
• The maximum permissible current density of copper in open air
is approximately 3.1×106 A/m2 of cross-sectional area, above
which it begins to heat excessively.
• Copper is one of a few metallic elements with a natural color
other than gray or silver. Pure copper is orange-red and
acquires a reddish tarnish when exposed to air.
• if copper is put in contact with another metal, galvanic
corrosion will occur.
 Name: Copper
Symbol: Cu
Atomic No: 29
Atomic Weight:
63.54gm
Phase: Solid
Melting
Native copper (~4 cm in size)
Point:1084.62ºC
Boiling Point: 2562ºC
Chemical properties of Copper
• Does not react with water
• Copper tarnishes when exposed to
some sulphur compounds, with which it reacts
to form various copper sulphides.
• Reacts with atmospheric oxygen
to form a layer of brown-black
copper oxide.
 Copper just above its
Unoxidized melting point keeps its
copper wire (left) pink luster color when
and oxidized enough light outshines the
copper wire orange
(right). Incandescence color.
A copper disc (99.95%
pure) made
by continuous
casting; etched to
reveal crystallites.

The East Tower of the Royal

Observatory, Edinburgh. The
contrast between the
refurbished copper installed
in 2010 and the green color of
the original 1894 copper is
clearly seen.
Uses of copper
Applications:
• Electrical wire(60%)
• Roofing and plumbing (20%)
• Industrial machinery (15%)
• Copper is used mostly as a pure metal, but when
greater hardness is required, it is put into such
alloys as brass and bronze (5% of total use)
• Copper paint has been used on boat hulls to control
the growth of plants and shellfish.
• Machining of copper is possible, although alloys
are preferred for good machinability in creating
intricate parts.
Manufacture of copper
• The ores usually pyrites are cleaned and crushed
and they are then calcined in a reverberatory
furnace ( a furnace in which the material that is
being treated is heated indirectly by flames that
are directed at the roof and walls of the furnace).
• The melted metal is oxidized in the bessemer
converter. It gives blister copper.(98% of copper)
• The impurities in the obtained copper are
removed by melting it in a reverberatory furnace
in presence of air.
• Slag is removed and pure copper to the extent of
about 99.7%is obtained.
Zinc- Occurrence
Zinc makes up about 75 ppm (0.0075%) of Earth's crust, making it
the 24th most abundant element. Soil contains zinc in 5–770 ppm
with an average 64 ppm. Seawater has only 30 ppb and the
atmosphere, 0.1–4 µg/m3.
The element is normally found in association with other base
metals such as copper and lead in ores. Zinc is a chalcophile, meaning
the element has a low affinity for oxides and prefers to bond
with sulfides. Chalcophiles formed as the crust solidified under
the reducing conditions of the early Earth's atmosphere. Sphalerite,
which is a form of zinc sulfide, is the most heavily mined zinc-
containing ore because its concentrate contains 60–62% zinc.
Other source minerals for zinc
include smithsonite (zinc carbonate), hemimorphite (zinc silicate), w
urtzite (another zinc sulfide), and sometimes hydrozincite (basic zinc
carbonate). With the exception of wurtzite, all these other minerals
were formed by weathering of the primordial zinc sulfides.
Physical properties of Zinc
• It is a bluish-white lustrous and
diamagnetic material .
• It is less denser than iron.
• The metal is hard and brittle at most
temperatures but becomes malleable at 100-150ºC.
• Above 210ºC the metal becomes brittle and can be
pulverized by beating.
• It is conductor of electricity.
• The melting point is the lowest of all the transition
metals aside from mercury and cadmium.
• Resists corrosion.
• It should be kept clear of lime and calcareous
substances.
 Name: Zinc
Symbol: Zn
Atomic No.:30
Atomic Weight:65.38gm
Phase : Solid
Zinc fragment sublimed and
Melting Point: 419.53ºC
cubed 1*1 cm Boiling Point: 907ºC
Chemical properties of Zinc

• Zinc is a fairly reactive metal that will

combine with oxygen and other non-
metals.
• It is a fair electrical conductor and will
react with dilute acids to release hydrogen
• Zinc does not react with water.
Uses of Zinc
• It is used in electric cells.
• Galvanizing
• Preparation of alloys
• Paints
• Has great value as a protective covering or a coat
to iron works, plain, corrugated sheets, iron
vessels.
• Lining to the drinking water storage tanks.
Manufacture of zinc

The zinc ore is heated in an electric furnace

to remove all volatile constituents present in
the ore. The zinc is liberated in the form of
vapour. This vapour is then condensed to
get a metallic zinc.
Physical properties of Tin
• It is soft malleable and ductile and
highly crystalline silvery white metal.
• When a bar of tin is bent, a crackling
sound known as the "tin cry" can be
heard from the twinning(assemblage of two or more
crystals) of the crystals.
• β-tin (the metallic form, or white tin), which is stable
at and above room temperature, is malleable.
• α-tin (nonmetallic form, or gray tin), which is stable
below 13.2 degC (55.8 degF), is brittle.
• It is capable of taking high polish and can easily be
welded.
Name: Tin
Symbol: Sn
Atomic No.:50
Atomic Weight:118.71gm
Phase: Solid
Melting Point:231.93ºC
Boiling Point: 2602ºC
Chemical properties of Tin
• Resists corrosion against water.
• Gets corroded by alkalies and acids
• Tin can be highly polished and is
used as a protective coat for other metals.
• A protective oxide (passivation) layer prevents
further oxidation, the same that forms on pewter
and other tin alloys.
• Tin acts as a catalyst when oxygen is in solution
and helps accelerate chemical attack.
Uses of Tin

• Soldering
• Tin plating
• Specialized alloys
• Pure tin is used for making evaporating basins,
infusion pots.
• Tin foils are also used for silvering of mirrors
and wrapping up cheese, chocs, tobacco, toilet
soaps.
Manufacture of Tin
• The ore is crushed and washed
to remove impurities.
• It is then calcined in a revolving
calciner.
• The calcined ore is allowed to cool.
• After cooling, it is washed with water.
• The liquid is then allowed to rest.
• The refined tinstone collects at the bottom as it is heavy.
• It is then smelted in a furnace with an anthracite coal
and sand.
• Finally it is finely refined in a reverberatory furnaced to
obtain commercially pure tin.
Physical properties of Lead
• Freshly prepared or fractured lead has a
bright silvery appearance with a very slight hint
of blue.
• Tarnishes on contact with moist air, forming
a complex surface mixture of compounds whose
color and composition will vary depending on the prevailing
conditions.
• Has high density, softness, malleability, ductility, poor electrical
conductivity compared to other metals, high resistance
to corrosion (conferred by its surface patina), and a propensity to
react with organic reagents.
• Lead is a very soft metal with a Mohs hardness of 1.5; it can be
scratched with a fingernail.
• It is malleable and ductile, with its malleability exceeding its ductility.
• Compressive strength of lead is high and it can therefore be rolled
into extremely thin sheets.
Name: Lead
Symbol: Pb
Atomic no.: 82
Atomic weight: 207.2gm
Phase: solid
Melting point: 327.46ºC
Boiling point: 1749ºC
 Chemical properties of Lead
• Finely divided powdered lead exhibits pyrophoricity
(A pyrophoric substance (from Greek πυροφόρος,
pyrophoros, "fire-bearing") ignites spontaneously in air at
or below 55 °C (130 °F).)
• It burns with a bluish-white flame
• Bulk lead exposed to moist air forms a protective layer of
varying composition.
• Lead is not attacked by dilute sulfuric acid; the
concentrated acid dissolves the metal thanks
to complexation.
• Lead reacts slowly with hydrochloric acid; nitric
acid reacts vigorously to form nitrogen oxides and lead(II)
nitrate. Organic acids, such as acetic acid, dissolve lead,
but this reaction requires the presence oxygen.
Uses of Lead
• Lead has been used for bullets since
their invention.
• Because of its high density and resistance
to corrosion, lead is used as ballast in
sailboat keels.
• It acts like a lubricant and, in low concentrations, also as a chip
breaker.
• To form glazing bars for stained glass or other multi-lit windows.
• In the construction industry (e.g., lead sheets are used
as architectural metals in roofing material, cladding, flashing,
gutters and gutter joints, and on roof parapets). Detailed lead
moldings are used as decorative motifs to fix lead sheet.
• In electrodes for the process of electrolysis. It is used in solder for
electronics, although this usage is being phased out by some
countries to reduce the amount of environmentally hazardous waste,
and in high voltage power cables as sheathing material to prevent
water diffusion into insulation.
Manufacture of Lead
• The ores are ground and sieved.
The impurities are segregated
out as far as practicable. The
separation is further accomplished in the
flotation machine.
• The coke and metallic iron are added to the ores.
• The mixture is then smelted in blast furnace.
• The impure lead is obtained which is further
purified in a reverberatory furnace.